High Temperature Materials. By Docent. N. Menad. Luleå University of Technology ( Sweden )

Transcription

1 Sintering and Consolidation of Ceramics Course KGP003 High Temperature Materials By Docent. N. Menad Dept. of Chemical Engineering and Geosciences Div. Of process metallurgy Luleå University of Technology ( Sweden )

2 Solid State Sintering Sintering and Consolidation of Ceramics The Phenomenon of Sintering What is Sintering? Sintering commonly refers to processes involved in the heat treatment of powder compacts at elevated temperatures, usually at T > 0.5Tm [K], in the temperature range where diffusional mass transport is appreciable. Successful sintering usually results in a dense polycrystalline solid. However, sintering can proceed only locally (i.e. at contact point of grains), without any appreciable change in the average overall density of a powder compact. Sintering is thermal treatment of fine-grained material at a temperature below the melting point of the main constituent, for the purpose of increasing its grain size and strength by bonding together the particles. Theories about what happens exactly during sintering have provided the subject matter of innumerable conferences and learned scientific papers. Suffice to say that atomic diffusion takes place and the welded areas formed during compaction grow until eventually may be lost completely. Re-crystallization and grain growth may follow, and the pores tend to become rounded and the total porosity, as a percentage of the whole volume, tends to decrease.

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4 Reconstructions (virtual slices) perpendicular to the cylindrical axis showing Cu particles at different stages of the sintering process: (a) before sintering, (b) after sintering at 1000 C, and (c) after sintering at 1050 C. Identical regions (inside the rectangle of (a)) are shown at a higher magnification below. Reconstructed slices of a compacted Distaloy sample before (a) and after (b) sintering at 1130 C. The direction of prior compaction is along the vertical direction in the paper plane

5 Development of sinter texture Development of sinter texture < 1300 C Coke Melting Point Residual hematite Hematite Fine mineral Clay > 1300 C Secondary hematite N. Menad, H. Tayibi, Fernando Garcia Carcedo and A. Hernández Minimization methods for emissions generated from sinter strands: a review J. of clean production, Pages , 2005

6 Basic Thermodynamics of Sintering Basic Thermodynamics of Sintering The driving force for sintering is a decrease in the surface free energy of powdered compacts, by replacing solid-vapor interfaces (of surface energy Γ SV ) with solid-solid (Γ SS ) interfaces, where Γ SS < Γ SV. Thermodynamically, then, sintering is an irreversible process in which a free energy decrease is brought about by a decrease in surface area.

7 Basic Thermodynamics of Sintering Basic Thermodynamics of Sintering At a typical specific surface S of ceramic powders S = 1-10 m 2 /g and Γ SV = 1-2 J/m 2. The resulting excess of surface energy of Γ SV = 1-20 J/g is small compared with the heat of chemical reactions (> 1 kj/g) but still sufficient to drive the sintering processes. Some mechanisms can lead to a waste of sintering driving force without assisting densification. These are the grain coarsening mechanisms, which are driven by the same force as sintering. The change of system energy de due to sintering is therefore composed of the increase due to the creation of new grain boundary areas, da SS > 0, and due to the annihilation of vapor-solid interfaces, da SV < 0. The necessary global thermodynamic condition for the sintering to proceed is de = Γ SS da SS + Γ SV da SV < 0 The sintering process will stop when de = 0 Γ SS da SS + Γ SV da SV = 0 or Γ SS / Γ SV = - da SV / da SS

8 Basic Thermodynamics of Sintering Basic Thermodynamics of Sintering The sintering progress can be represented by plotting the total free surface area A SV, vs the total surface area of the grain boundaries A SS. At the start of sintering, all surface area equals the free surface area, since no grain boundaries exist yet, A SV = AS V0 and A SS = 0. As sintering proceeds, A SV decreases and A SS increases, in such a way that a monotonically decreasing curve is obtained with the slope -da SV / da SS. If, at any point during sintering, the value of the slope reaches Γ SS / Γ SV, the sintering must stop due to the above equilibrium condition. The principal objective of sintering is the elimination of porosity, i.e. a minimum A SV, possibly A SV =0 and A SS large, meaning little grain growth. It is thus desirable that the sintering stop condition is reached when the slope da SV / da SS close to zero, i.e. Γ SS << Γ SV. Through this type of thermodynamic considerations it is suggested that sintering can be encouraged through manipulation of the doping and/or the environment, so the surface energy is maximized.

9 Classes (Categories) of Sintering Classes (Categories) of Sintering The majority of non-silicate ceramics are processed through high-temperature treatment and sintering of powder compacts with little (<2 vol%) or no liquid phases. This is defined as Solid State Sintering, with predominant mass transport (i.e. densification mechanism) through solid-state diffusion. However, most silica-containing ceramics, including traditional porcelains as well as advanced silicon nitride, sinter in the presence of viscous glass-type liquids, with predominant mass transport (i.e. densification mechanism) through viscous flow. This is defined as Viscous Sintering. If the liquid component of the sintering system has low viscosity (e.g. molten cobalt in the classical system of WC/Co) the process is defined as Liquid Sintering. In this system the predominant densification mechanism is through rearrangement of the solid particles submerged in and wetted by the low viscosity liquid, and through dissolution and re-precipitation of the solid.

10 Why Ceramics have to be sintered? Why Ceramics have to be sintered? Ceramic processing is based on the sintering of powder compacts rather than melting/solidification/cold working (characteristic for metals), because: ceramics melt at high temperatures solidified microstructures can not be modified through additional plastic deformation and re-crystallization due to brittleness of ceramics. the resulting coarse grains would act as fracture initiation sites. low thermal conductivities of ceramics (<30-50 W/mK), in contrast to high thermal conductivity of metals (in the range W/mK) cause large temperature gradients, and thus thermal stress and shock in melting-solidification of ceramics. However, some ceramic refractories, such as Al2O3, Al2O3/ZrO2, are manufactured through the melting / casting / solidification process. If made properly, they are superior to the sintered versions, and the processing costs of large, ~ 1 m tall blocks is lower.

11 Why do we need Sintering? Why do we need Sintering? The principal goal of sintering is the reduction of compact porosity. Sometimes the initial spaces between compacted grains of ceramics are called voids, to differentiate them from the isolated spaces = pores, which occur in the final stages of sintering. The sintering process is usually accompanied by other changes within the material, some desirable and some undesirable. The largest changes occur in - strength, elastic modulus - hardness, fracture toughness - electrical and thermal conductivity - permeability to gases and liquids - average grain number, size and shape - distribution of grain size and shape - average pore size and shape - distribution of pore size and shape - chemical composition and crystal structure

12 Why do we need Sintering? Why do we need Sintering? Sintering is a widely used but very complex phenomenon. The fundamental mechanisms of sintering are still a matter of controversy. Experimental quantification of changes in pore fraction and geometry during sintering can be attempted by several techniques, such as: - Dilatometry - Buoyancy - Gas absorption - Porosimetry - Indirect methods (e.g. hardness) - Quantitative microscopy

13 The description of the sintering process has been derived from model experiments (e.g. sintering of a few spheres) and by observing powdered compact behavior at elevated temperatures. The following phenomena were observed and modeling was attempted: - increase of inter-particle contact area with time - rounding-off of sharp angles and points of contact - in most cases, the approach of particle centers and overall densification - decrease in volume of interconnected pores - continuing isolation of pores - grain growth and decrease in volume of isolated pores The development of microstructure and densification during sintering is a direct consequence of mass transport through several possible paths (one of these paths is usually predominant at any given stage of sintering): - GAS phase (evaporation/condensation) - LIQUID phase (solution/precipitation) - SOLID phase (lattice diffusion) - INTERFACES (surface diffusion, grain boundary diffusion) - VISCOUS or PLASTIC FLOW, under capillary pressure (internal) or externally applied pressure (pressure-sintering, hot-pressing, hot-isostatic-pressing) Since certain mechanisms of mass transport can be dominant in some systems, two broad categories of sintering are recognized:

14 where all densification is achieved through changes in particle shape, without particle rearrangement or the presence of liquid where some liquid that is present at sintering temperatures aids compaction. Grain rearrangement occurs in the initial stage followed by a solution-re-precipitation stage. Usually, the liquid amount is not sufficient to fill the green-state porosity in normal liquid-assisted sintering of ceramics. In many instances, supposedly Solid State Sintering proceeds in the presence of previously undetected (or transient) small amounts of liquid (perhaps introduced as impurities during the powder preparation stage, such as silicates in oxide ceramics Al2O3, ZrO2). Simple model experiments with spheres or rods illustrate sintering phenomena, classified into three stages of sintering, as discussed below.

15 1. Initial stage of sintering, involving 1A. Local point of contact formation or "fusion", without shrinkage of compact. This is accompanied by smoothing of the free surface of particles. 1B. Neck formation at the contact point, with the resulting concave curvature δn (where δn =1/rn) at the neck, in contrast to the convex curvature on the particle surface of radius r, where r >> r n. The two radiuses of the neck curvature, r n and y, represent an experimental justification for the two-sphere model of sintering. The processes 1A and 1B result in densification of the sintering component by ~10%. That is, if the relative green density after forming of the particle compact was 60%, the density after initial stage would be about 70% of the theoretical density TD. However, the 10% densification in the initial stage is reached very quickly (seconds or minutes) after exposing powder to high temperature, because of the large surface area and the high driving force for sintering.

16 2. Intermediate stage of sintering, involving 2A. neck growth, 2B. pores forming arrays of interconnected cylindrical channels, 2C. particle centers approaching one another, with the resulting compact shrinkage. The shrinkage in the intermediate stage can result in additional densification by as much as 25%, or to a total of about 95% of the TD (theoretical density), compare. However, shrinkage does not necessarily have to take place during the intermediate stage of sintering. For example, shrinkage would not occur if matter was transported FROM the particle SURFACE, and proceeded through either gas, solid or along interface as surface diffusion.

17 3. Final stage of sintering, involving: 3A. Isolation of pores, i.e. relative density exceeding ~93% 3B. Elimination of porosity 3C. Grain growth The final sintering stage begins at about 93-95% of theoretical density, when porosity is already isolated. Ideally, at the end of this stage all porosity is eliminated. The complete elimination of porosity in the final stage of sintering can only happen when all pores are connected to fast, short diffusion paths along grain boundaries (or, equivalently, if the grain boundaries remain attached to the pores).

18 Sintering process Before sintering After sintering

19 Sintering A(s) + B(s) AB(l) L A+L B+L A+B A 1 2 B

20 Empirical Modeling of Sintering Empirical Modeling of Sintering A large number of equations describing the variation of porosity P/P 0 (or shrinkage ΔL/L 0 ) versus time t have been proposed. All of these equations use simplified assumptions of idealized models, or are based purely on empirical observations. These equations usually have forms of: P/P 0 = ( a + bt )c or P - P 0 = dln(t/t 0 ) or (ΔL/L 0 )n = at, where: a,b,c,n = constants. A remarkable feature of most of these equations is that, using curve-fitting procedures, a nearly perfect fit can be obtained with experimental data on sintering. However, little or no insight into sintering mechanisms is obtained and incorrect conclusions are drawn when physical meanings are attributed to the fitted constants. This is because real systems deviate significantly from idealized models: *particles are non-uniformly distributed in space and rearrange during sintering *necks grow asymmetrically *different sintering stages (neck formation, neck growth, rearrangement, grain growth with or without shrinkage, closed porosity sintering) are controlled by different mechanisms which interact and overlap in a complex way

21 The mass transport from surfaces: evaporation-condensation The mass transport from surfaces: evaporation-condensation The mass transport can proceed through a gas phase, driven by a differential in vapor pressure. Evaporation-condensation takes place because the vapor pressure p 1 on a curved surface of radius r 1 is different from that on a flat surface (p 0, r 0 = ) or any other surface at r 2. This is expressed by the Kelvin equation: ln (p 1 /p 2 ) = (Ω Γ SV / RT) (1/r 1 + 1/r 2 ) where Ω = the molar volume of the species. For the simple case of r 2 = r 0 = and p 2 = p 0 (that is, for a flat surface), the above equation simplifies to: ln (p 1 /p 2 ) (p 1 -p 0 )/p 0 = Δp/p 0 so Δp/p 0 = (Ω Γ SV )/(R T r 1 )

22 The mass transport from surfaces: evaporation-condensation The mass transport from surfaces: evaporation-condensation The most important case of evaporationcondensation mass transport is from the surface of convex (spherical) particles (r > 0) to the surface of concave necks (r n < 0) where r n << r at the contact region. No shrinkage occurs in this process and y 3 is a linear function of time: y 3 = α 2 t and h/r = ΔL/L = 0 This type of transport dominates at the relatively high vapor pressures of 10-4 atmospheres, found for halides (e.g. NaCl at 700 C). The loglog plot of the neck size versus time has a slope close to 1/3. The evaporation-condensation process is suspected to stop the sinterability of some non-oxide ceramics (such as SiC, B4C) at very high temperatures > 2100 C

23 The The model model for for mass mass transport from from surfaces: surface surface or or volume volume diffusion from from surface, DS DS Similar to evaporation-condensation, no shrinkage results from the other two mechanisms of mass transport from particle surfaces to necks through the two possible diffusion paths. (I) volume diffusion from particle surfaces to necks: y 4 = α 3 t and h/r = ΔL/L = 0 (II) surface diffusion, along particle surfaces to necks: y 7 = α 4 t and h/r = ΔL/L = 0

24 The The model model for for mass mass transport from from within within the the particle volume or or from from the the grain grain boundary, DL DL or or DB DB For mass transfer originating in the particle volume or at the grain boundary, the particle centres approach (h > 0) and shrinkage takes place. (I) for volume diffusion from grain boundary: y 5 = α 5 t and thus (h/r) 2.5 = (ΔL/L) 2.5 = β 5 t (II) for grain boundary diffusion from grain boundary: y 6 = α 6 t and thus (h/r) 3 = (ΔL/L) 3 = β 6 t

25 . Examples of Solid State Sintering Since ceramics are composed of at least two elements (typically oxygen or nitrogen and metal ions) Both ionic species must diffuse together to maintain the electrical neutrality of the system. Therefore, it is the diffusion coefficient of the slowest moving ion along its fastest path that controls mass transfer, and therefore densification during solid state sintering. To enhance sintering, the slowest moving ion must be identified and its diffusion along the fastest path should be "encouraged" through: Chemical doping, Atmospheric control An appropriate time/temperature cycle

26 Sintering of MgO MgO MgOsintering proceeds through lattice lattice diffusion. Diffusion of of magnesium is is faster faster than than oxygen, D Mg O. The rate Mg > D O. The sintering rate is is increased if if the the diffusivity of of oxygen oxygen is is increased through the the creation of of additional oxygen oxygen vacancies through doping doping with with M2O M2O (for (for example Na2O). Na2O). Sintering of Al2O3 Another example of of solid solid state state sintering is is the the sintering of of Al2O3. Al2O3. Initially, it it was was observed, that that small small additives of of MgO MgO (0.25 (0.25 wt%) wt%) in in Al2O3 Al2O3 allow allow the the achievement of of fine-grained material at at full full density density (which (which is is the the ceramist s dream). Additional microstructural observations revealed that that MgO MgO eliminates the the micro- discontinuous grain grain growth growth of of Al2O3. Al2O3. It It was was found found that that grain grain boundaries do do not not break break away away from from the the pores, pores, which which prevents the the inclusion of of pores pores trapped inside inside new new large large grains, grains, with with slow/long diffusion paths paths for for densification. The The mechanism by by which which MgO MgO slows slows down down grain grain boundary movement in in alumina could could be be as as follows follows

27 - The majority of MgO doped into Al2O3 resides at the grain boundaries, because the dissolution of MgO in Al2O3 is small, ~300 ppm. This is due to the relatively large difference in ionic radius: 0.72A for Mg2+ and 0.53A for Al3+ - Any fast migration of the grain boundary would have to incorporate Mg2+ ions into the Al2O3 lattice, with the resulting increase in internal energy, unless a NEW compound, spinel, forms. Arguments on the role of MgO in Al2O3 sintering continue at the present tim Note that other grain-growth inhibitors can be added to Al2O3. For example, submicron ZrO2 particles (10-20 vol%) residing at the triple points of grain boundaries of alumina effectively inhibit grain growth according to the equation: r 4 -r 04 = a t, where: r = the average particle size after time t, r 0 = the average initial particle size at t=0, and a = constant.

28 Sintering of SiC Pressureless sintered SiC requires B and C as additives, which affect the relative diffusion coefficients. Presence of silica impurities in SiC can enhance evaporation-condensation mechanisms through a volatilization reaction 2SiO2 (solid) + SiC (solid) 3SiO(gas) +CO (gas) Carbon removes SiO2 and Si from the surface of SiC according to the carbothermal reduction reaction: SiO2 + 3C SiC + 2CO; C+Si SiC Thus, fewer defects are present at the surface and diffusion along the surface decreases. This slows down the coarsening mechanisms. Simultaneously, boron has been found to selectively segregate toward grain boundary regions, where its role is unclear, i.e. it is suspected that:

29 Pressure Assisted Sintering Pressure Assisted Sintering - Technology Pressure assisted sintering increases the contact pressure of particles and thus the driving force for sintering, compared to pressureless solid state sintering by ~ one order of magnitude in hot pressing (HP) at MPa pressure by ~ two orders of magnitude in hot isostatic pressing (HIP) at MPa pressure

30 Example of Viscous Sintering: Porcelains Sintered nano barium titanate

31 NETZSCH Dilatometer 402 C Equipment Materials Measurement Powdered metal and composite materials Thermal expansion and sintering behaviour figure shows the thermal expansion and rate of expansion of a silicon nitride green body. The sintering step starting at 1201 C is due to the influence of the sintering additives. The main shrinkage step occurred at 1424 C (extrapolated onset). The effect above 1760 C is most probably due to evaporation of additives

32 The Laser Sintering Process Certain proportion of the laser energy is transformed into heat, this depends upon the powder material and its characteristics. Laser output can be minimised through maintaining the powder at a temperature just below its melting point

33 Selective Laser Sintering (SLS) This process is a well known procedure for rapid tooling/prototyping. Its principle is the following: A powder made from synthetic materials, coated metal powder or mixture of metal powders is deposited in a thin layer. In a next step a Laser beam heats and melts the powder either partially or fully. Repeated application of this procedure creates rapidly full scale objects in one manufacturing step Surface treated by with SLS This Figure shows a cut through a sintered aluminiumbronze part. The part has a dense structure with fine grains. Therefore, manufacturing metal foring tools by selective Laser-Sintering seems to be a valuable alternative to conventional manufacturing procedures

34 Sintering Practice Exercises 1. Name 5 different changes that can occur during heating of a ceramic material. 2. What are the 3 principal sintering processes? 3. What does liquid sintering mean? 4. What does viscous sintering (vitrification) mean? 5. What are the main driving forces during sintering? 6. What are the main driving forces during actual solid state sintering? 7. Which transport mechanisms occur during solid state sintering? 8. What is the effect of increased temperature on solid state sintering? 9. Name at least 4 parameters that are crucial during solid state sintering? 10. Describe the different stages of solid state sintering. 11. What requirements must be fulfilled in order to attain total pore elimination during solid state sintering? 12. Why is sintering easier in the presence of a liquid phase? 13. Describe the reaction mechanisms during liquid sintering. 14. How does vitrification differ form normal liquid sintering? 15. During the study of a solid sintering process at constant temperature it was discovered that the neck radius, y, is proportional to t 0.2. What is the dominating transport mechanism in this sintering process?